Collet Chuck Hub Shaft Caulking Deformation Control

Solution Overview

Problem

The existing methods for manufacturing rolling bearing devices for wheels face challenges such as radially inward plastic deformation of the hub shaft during the caulking process, leading to increased manufacturing costs and reduced bearing rigidity, and potential damage to the engaging portions due to the use of column-shaped jigs.

Innovation Solution

A method utilizing a collet chuck with radially expandable and contractable separated portions to support the hub shaft from the inside during caulking, preventing plastic deformation and reducing the risk of damage to the engaging portions by expanding and contracting to maintain contact with the hub shaft without forming clearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a column-shaped metallic jig is used to prevent radially inward plastic deformation of the through hole during caulking, then the deformation is prevented, but the jig may damage the spline portion of the hub shaft due to difficulty in insertion and extraction

Engineering Contradiction:

Improvethrough hole deformation controlVSAvoiddamage to spline portion

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The support device is divided into a body portion and multiple plate-like support portions that can be radially expanded and contracted. This segmentation allows the support portions to be inserted into the through hole in a contracted state, avoiding damage to the spline portion, and then expanded to provide support during caulking to prevent through hole deformation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support portions are designed to be radially movable between a contracted state for insertion/extraction and an expanded state for support during caulking. This dynamic configuration allows the device to adapt its shape to avoid damaging the spline portion while maintaining support functionality during the caulking process.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the end of the hub shaft is caulked by bending radially outward, then the rolling bearing is secured, but radially inward plastic deformation occurs in the through hole requiring additional broach process

Engineering Contradiction:

Improverolling bearing retentionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The support portions are positioned and expanded in advance before the caulking process begins. This preliminary action provides pre-support to the through hole, preventing radially inward plastic deformation during the subsequent caulking operation, thereby eliminating the need for broach process and reducing manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plate-like support portions act as an intermediary between the caulking load and the through hole. They distribute and transfer the forces during caulking to prevent direct radially inward deformation of the through hole, while still allowing the end to be caulked effectively for securing the rolling bearing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the end of the hub shaft is caulked by bending radially outward, then the rolling bearing is secured, but radially inward plastic deformation occurs reducing bearing rigidity

Engineering Contradiction:

Improverolling bearing retentionVSAvoidbearing rigidity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The support portions are positioned and expanded in advance before the caulking process begins. This preliminary action provides pre-support to the through hole, preventing radially inward plastic deformation during the subsequent caulking operation, thereby eliminating the need for broach process and reducing manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plate-like support portions act as an intermediary between the caulking load and the through hole. They distribute and transfer the forces during caulking to prevent direct radially inward deformation of the through hole, while still allowing the end to be caulked effectively for securing the rolling bearing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach eliminates the need for additional processes like broaching, saves manufacturing costs, maintains bearing rigidity, and minimizes damage to the engaging portions by supporting the hub shaft internally during caulking.

Implementation Method 1

a collet chuck that includes a cylindrical portion and a plurality of separated portions formed by separating the cylindrical portion in an axial direction, the plurality of separated portions being radially expandable

Methodology Applied

Scientific EffectRadial expansion and contraction: Elasticity

Data Source

PatentUS7900358B2Method of manufacturing rolling bearing device for wheel

Publication Date: 2011.03.08 JTEKT CORP

AI summary

A method of manufacturing a double row rolling bearing device includes: providing a collet chuck having radially expandable separated parts and a tapered cone for radially expanding the separated parts; inserting the radially contracted collet chuck into a through hole before the double row rolling bearing is caulked to the hub shaft; caulking the cylindrical end of the hub shaft, with the separated parts being in contact with the end by radially expanding the collet chuck to prevent radially inward plastic deformation of the end; and contracting the collet chuck and extracting the collet chuck out of the hub shaft after the caulking.